U.S. patent application number 13/408346 was filed with the patent office on 2013-08-29 for method of detecting material in a part.
The applicant listed for this patent is Kevin D. Smith, Jeffrey A. Umbach. Invention is credited to Kevin D. Smith, Jeffrey A. Umbach.
Application Number | 20130223672 13/408346 |
Document ID | / |
Family ID | 49002906 |
Filed Date | 2013-08-29 |
United States Patent
Application |
20130223672 |
Kind Code |
A1 |
Smith; Kevin D. ; et
al. |
August 29, 2013 |
METHOD OF DETECTING MATERIAL IN A PART
Abstract
A method includes the steps of producing a first digital x-ray
image of a part utilizing a full energy spectrum, producing a
second digital x-ray image of the part with a hardened beam
correlating to a higher energy portion of the full energy spectrum,
subtracting the second x-ray image from the first x-ray image, and
using a remainder of the subtracting step to locate the matter.
Inventors: |
Smith; Kevin D.;
(Glastonbury, CT) ; Umbach; Jeffrey A.; (Palm
Beach Garden, FL) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Smith; Kevin D.
Umbach; Jeffrey A. |
Glastonbury
Palm Beach Garden |
CT
FL |
US
US |
|
|
Family ID: |
49002906 |
Appl. No.: |
13/408346 |
Filed: |
February 29, 2012 |
Current U.S.
Class: |
382/100 ;
382/190 |
Current CPC
Class: |
G01N 23/18 20130101;
G01N 2223/423 20130101; G01N 23/087 20130101; G01N 23/083 20130101;
G01N 2223/41 20130101; G01N 23/04 20130101; G01N 2223/424 20130101;
G01N 2223/652 20130101; G01N 2223/63 20130101 |
Class at
Publication: |
382/100 ;
382/190 |
International
Class: |
G06K 9/46 20060101
G06K009/46 |
Claims
1. A method for detecting matter in a part comprises the steps of:
producing a first x-ray image of a part utilizing a full energy
spectrum, producing a second x-ray image of said part utilizing a
beam correlating to a higher energy portion of said full spectrum,
subtracting said second x-ray image from said first x-ray image,
and using a remainder of said subtracting step to locate the
matter.
2. The method of claim 1 wherein said producing a first x-ray image
step includes creating a first image of said x-rayed part.
3. The method of claim 2 wherein said producing a second x-ray
image step includes creating a second image of said x-rayed
part.
4. The method of claim 3 wherein said subtraction step includes
creating a third image of said x-rayed part.
5. The method of claim 1 further comprising: enhancing said
remainder for detection by a user or through automated algorithms
of said unwanted matter.
6. The method of claim 1 further comprising: creating an image of
said remainder in which said unwanted matter is displayed.
7. The method of claim 6 further comprising: enhancing said
remainder for detection by a user or through automated algorithms
of said unwanted matter.
8. The method of claim 1 wherein said part is in a same position
during said x-raying steps.
9. A method for detecting matter relating to an airfoil comprises
the steps of: producing a first x-ray image of a blade utilizing a
full energy spectrum, producing a second x-ray of said blade with a
beam correlating to a higher energy portion of said full spectrum,
subtracting said second x-ray image from said first x-ray image,
and using a remainder of said subtracting step to locate the
matter.
10. The method of claim 9 wherein said full spectrum is between
60-650 Kv.
11. The method of claim 9 wherein said hardened beam is between
300-650 Kv.
12. The method of claim 9 wherein said producing a first x-ray step
includes creating a first image of said x-rayed part, said
producing a second x-ray step includes creating a second image of
said x-rayed part and said subtraction step includes creating a
third image of said x-rayed part.
13. The method of claim 9 further comprising: enhancing said
remainder for detection by a user or through automated algorithms
of said matter.
14. The method of claim 9 further comprising: creating an image of
said remainder in which said unwanted matter is displayed.
15. The method of claim 14 further comprising: enhancing said
remainder for detection by a user or through automated algorithms
of said matter.
16. The method of claim 9 wherein said part is in a same position
during said x-raying steps.
17. A method for detecting unwanted matter relating to a blade for
a gas turbine engine comprises the steps of: producing a first
x-ray image of a blade utilizing a full energy spectrum, producing
a second x-ray image of said blade with a beam correlating to a
higher energy portion of said full spectrum, subtracting said
second x-ray from said first x-ray, and using a remainder of said
subtracting step to locate the matter.
18. The method of claim 17 wherein said full spectrum is between
60-650 Kv and said hardened beam is between 300-650 Kv.
19. The method of claim 17 further comprising enhancing said
remainder for detection by a user or through automated algorithms
of said matter.
20. The method of claim 17 wherein said producing a first x-ray
image step includes creating a first image of said x-rayed part,
said producing a second x-ray image step includes creating a second
image of said x-rayed part and said subtraction step includes
creating a third image of said x-rayed part.
Description
BACKGROUND
[0001] Detection of materials that are present within another
material using x-rays is particularly difficult if the surrounding
material has a significantly higher x-ray absorption
characteristic. For such cases, higher x-ray energies are required
to penetrate and evaluate the surrounding material which can make
the materials with low absorption characteristics essentially
invisible in the resulting x-ray image.
[0002] An example of such a case is the detection of casting core
material within the metal structure of aerospace components. While
the core material is intended to be completely removed before part
usage, a costly neutron radiographic procedure is typically invoked
to detect residual core material that would be detrimental to the
part if left in the part.
[0003] There is a need to be able to detect the presence of
material with low x-ray absorption characteristics in the presence
of material with high x-ray absorption characteristic in a timely
and cost effective manner. In particular, using the method for
detection of low x-ray absorption material in conjunction with
x-ray inspections already used for inspection of other
characteristics of the component such as the presence of voids
would provide an especially efficient inspection process.
SUMMARY
[0004] An exemplary method disclosed herein includes the steps of
producing a first digital x-ray image of a part utilizing a full
x-ray spectrum, producing a second digital x-ray image of the part
utilizing a higher energy portion of the full spectrum, subtracting
the second x-ray image from the first x-ray image, and using a
remainder of the subtracting step to locate certain matter.
[0005] In another embodiment of the exemplary method of any of the
preceding paragraphs, the method includes creating a first digital
x-ray image of the part.
[0006] In another embodiment of the exemplary method of any of the
preceding paragraphs, the method includes creating a second digital
x-ray image of the part.
[0007] In another embodiment of the exemplary method of any of the
preceding paragraphs, the method includes creating a third digital
x-ray image of the part.
[0008] In another embodiment of the exemplary method of any of the
preceding paragraphs, the method includes enhancing the remainder
for detection by a user or through automated algorithms, of the
matter.
[0009] In another embodiment of the exemplary method of any of the
preceding paragraphs, the method includes creating an image of the
remainder in which the matter is displayed.
[0010] In another embodiment of the exemplary method of any of the
preceding paragraphs, the method includes a limitation wherein the
part is in a same position during the x-raying steps.
[0011] A further exemplary method disclosed herein includes the
steps of producing a first digital x-ray image of a blade utilizing
a full x-ray spectrum, producing a second digital x-ray image of
the blade with a hardened beam correlating to an upper portion of
the full spectrum, subtracting the second x-ray image from the
first x-ray image, and using a remainder of the subtracting step to
locate matter.
[0012] In another embodiment of the exemplary method of any of the
preceding paragraphs, the method includes the limitation the full
spectrum is between 60-650 Kv.
[0013] In another embodiment of the exemplary method of any of the
preceding paragraphs, the method includes the limitation wherein
the hardened beam is between 300-650 Kv.
[0014] In another embodiment of the exemplary method of any of the
preceding paragraphs, the producing a first x-ray step includes
creating a first image of the x-rayed part, the producing a second
x-ray step includes creating a second image of the x-rayed part and
the subtraction step includes creating a third image of the x-rayed
part.
[0015] In another embodiment of the exemplary method of any of the
preceding paragraphs, the method includes enhancing the remainder
for detection by a user or through automated algorithms, of the
matter.
[0016] In another embodiment of the exemplary method of any of the
preceding paragraphs, the method includes creating an image of the
remainder in which the matter is displayed.
[0017] In another embodiment of the exemplary method of any of the
preceding paragraphs, the method includes a limitation wherein the
part is in a same position during the x-raying steps.
[0018] A still further exemplary method disclosed herein includes
the steps of producing a first digital x-ray image of a blade
across a full spectrum, producing a second x-ray of the blade with
a hardened beam correlating to an upper portion of the full
spectrum, subtracting the second x-ray from the first digital x-ray
image, and using a remainder of the subtracting step to locate
matter.
[0019] In another embodiment of the exemplary method of any of the
preceding paragraphs, the method includes a limitation wherein the
full spectrum is between 60-650 Kv and a hardened beam is between
300-650 Kv.
[0020] In another embodiment of the exemplary method of any of the
preceding paragraphs, the method includes enhancing the remainder
for detection by a user or through automated algorithms, of the
matter.
[0021] In another embodiment of the exemplary method of any of the
preceding paragraphs, the method includes a limitation wherein the
producing a first x-ray step includes creating a first digital
image of the x-rayed part, the producing a second x-ray step
includes creating a second digital image of the x-rayed part and
the subtraction step includes creating a third digital image of the
x-rayed part.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] The various features and advantages of the present
disclosure will become apparent to those skilled in the art from
the following detailed description. The drawings that accompany the
detailed description can be briefly described as follows.
[0023] FIG. 1 shows an apparatus for x-raying a part.
[0024] FIG. 2A shows a first x-ray image of a blade with a first
x-ray spectrum using the apparatus of FIG. 1.
[0025] FIG. 2B shows a second x-ray image of a blade with a second,
overlapping second x-ray spectrum using the apparatus of FIG.
1.
[0026] FIG. 2C shows a view of the part wherein the second x-ray
image is subtracted from the first x-ray image using the apparatus
of FIG. 1.
[0027] FIG. 3 shows a method of detecting matter in a part using
the apparatus of FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0028] Referring now to FIG. 1, an x-ray system 5, includes an
x-ray source 10, as is known in the art, a part (such as a blade
15) to be x-rayed and a digital x-ray detector 20. The x-ray
detector 20 is connected to a general purpose computer 25 which
receives information from the digital x-ray detector 20. The x-ray
source is driven by a controller 29.
[0029] Referring now to FIGS. 2A, 2B, 2C, the blade 15 may be used
in the turbine environment in a gas turbine engine (not shown). The
blade 15 has an airfoil 40, a base 45, a platform 50 and an air
passage 55. Referring to FIG. 2A, a first image 60 of an x-ray of
the blade 15 is displayed including its airfoil 40, base 45,
platform 50 and the air passage 55. The blade 15 may be made as
noted above of titanium or nickel alloys or the like. For an
exemplar, the blade 15 shown herein is made of a nickel alloy.
[0030] FIG. 2A shows a first image 60 created in a first plurality
of pixels (not shown) in which the x-ray source 10 bombards the
blade 15 with a full spectrum of energy between 60 and 650
kilovolts ("Kv") as shown in graph 37. The data that is recorded at
the detector reflects the absorption characteristics of the
unwanted material as well as the parent material of the blade 15.
The resultant image, however, is overwhelmed by the highly
attenuative parent material. For instance, one can see the main
elements of the blade 15 including the airfoil 40, the base 45, the
platform 50 and the air passage 55. The first image 60 forms a
first part 100 (see FIG. 3) of the process. One of ordinary skill
in the art will recognize that other full spectrum energy levels
may be required for different materials, or for thicker or thinner
portions of other parts 15.
[0031] In image 60 of FIG. 2A, one cannot see any foreign material
or defects 65 (see residual ceramic core particles 70 in FIG. 2C)
very well. Such material or defect 65 may also be disposed in the
blade 15 and may include dross or other low density particles,
porosity, micro-shrinkage, grain boundary separation, or the
like.
[0032] As a second part 110 (see FIG. 3) of the process and as
shown in FIG. 2B, a hardened beam (e.g., a spectrum between 300 to
650 Kv or a higher range of the full spectrum of energy--see graph
71) is used to bombard the part 15 to create second image 75,
typically with the same plurality of pixels (not shown). By using
such higher energy, a second image 75 is shown of the structure of
the blade 15, including the airfoil 40, the base 45, the platform
50 and the air passage 55. One of ordinary skill in the art will
recognize that other hardened beams having different ranges of
energy may be required to be used for different materials, or for
thicker or thinner portions of other parts 15. One should also note
that the first image 60 and the second image 75 is taken while the
part 15 is in the same position. There are no registration issues
of the two images 60, 75 thereby.
[0033] To reveal the material 65, and as a third part 120 (see FIG.
3) of the process, a third image 80 (see FIG. 2C) is created to
allow the material 65 to be seen. The second image 75 is subtracted
from the first image 60 on a pixel-by-pixel basis within the
general purpose computer 25. The pixels that display in FIG. 2C are
essentially the remainder of the subtraction step 120. As shown in
graph 91 of FIG. 2C, the spectrum shown relates to the energy in
the 60-300 Kv range.
[0034] As a fourth part 130 (see FIG. 3) of the process, the
computer processes the third image 80 to enhance an image 90 of the
matter 65 by using an automated algorithm 95 as is known in the art
residing in general purpose computer 25. As known in the art, the
computer 25 in conjunction with the x-ray detector 20 captures a
number of counts of x-rays strikes in a pixel of the x-ray detector
that relate to each portion of the part 15 as the part is bombarded
over a given period of time. The unwanted matter 65 is not easily
seen in the full x-ray spectrum image because the image is
overwhelmed by the denser materials shown in FIGS. 2A and 2B. Yet
after the subtraction of the second image 75 from the first image
60, the effects of the blade geometry can be eliminated (see FIG.
2C and graph 91). The unwanted matter 65 also may not show, without
enhancement, if a full spectrum x-ray between 60 and 300 kilovolts
is taken because the image data is overwhelmed by the attenuation
characteristic of part 15.
[0035] As a fifth part 140 (see FIG. 3) of the process, the part 15
such as blade 15 may be scrapped, repaired or reprocessed depending
on the severity of the unwanted matter or defect 65 present.
[0036] One of ordinary skill in the art will recognize that this
process may be used in determining the presence of material that
does not belong in an environment, such as the human body, or other
bodies where harder materials that attenuate more may exist, e.g.,
as a stent. This process may require more exact manipulation of the
breadth of the full x-ray spectrum and the hardened beams to allow
for unwanted material to be seen. One of ordinary skill in the art
will recognize that, while two dimensional images 60, 75 and 80 are
shown herein, as technology advances, more than two dimensional
images may be created and use the teachings herein.
[0037] Although a combination of features is shown in the
illustrated examples, not all of them need to be combined to
realize the benefits of various embodiments of this disclosure. In
other words, a system designed according to an embodiment of this
disclosure will not necessarily include all of the features shown
in any one of the Figures or all of the portions schematically
shown in the Figures. Moreover, selected features of one example
embodiment may be combined with selected features of other example
embodiments.
[0038] The preceding description is exemplary rather than limiting
in nature. Variations and modifications to the disclosed examples
may become apparent to those skilled in the art that do not
necessarily depart from the essence of this disclosure. The scope
of legal protection given to this disclosure can only be determined
by studying the following claims.
* * * * *